⚖️ Line Balancing, or line balancing, is a production engineering technique that seeks to evenly distribute tasks among workstations on a production line, so that all stations operate with similar times, without bottlenecks or idleness.
A balanced line reduces waste, improves flow, and increases productivity without investing in new resources.
🧩 Why balance a production line?
- Avoids accumulation of parts between stations (WIP)
- Eliminates idle time for operators or machines
- Reduces the total cycle time of the line
- Ensures each station operates close to the Takt Time
- Improves flow quality and facilitates visual management
🔄 How to identify imbalances?
You can observe:
- Stations with queues or accumulation of DUTs
- Operators waiting for parts or testers free for too long
- High variation in cycle time per station
- Frequent activations of Andon for delays
🛠️ How to perform line balancing?
- Map all tasks per station (with average time per piece)
- Calculate the Takt Time (ideal production pace)
- Redistribute tasks so that each station operates close to Takt
- Validate the new configuration with simulations and real data
- Monitor performance with dashboards and indicators (e.g., OEE, cycle time, production rate)
🔧 How AJOLLY Testing applies Line Balancing
At AJOLLY Testing, we use Line Balancing to design test benches, jigs, and inspection processes in sync with other stages of the line.
Practical examples:
- Creation of parallel testers for long-duration DUTs
- Standardization of test time with automated instrumentation
- Reports of average time per operator or station
- Identification of top delays and task redistribution with the support of dashboards
- Integration with MES and Takt Time for continuous balancing review
📈 Direct benefits
| Benefit | Impact on operation |
|---|---|
| Reduction of cycle time | Increases production with the same resources |
| Better use of labor | Avoids idleness and overload |
| Lower WIP | Reduces accumulation of parts between stations |
| More predictable tests | Constant flow of DUTs for analysis |
| Support for continuous improvement | Clear data for corrective and preventive actions |
With Line Balancing, AJOLLY Testing helps your factory produce more, with less time, less rework, and more control — without needing more space or machines.